Electromagnetic relay and contact carrier assembly therefor



Nov. 2, 1965 M. HURTER ETAL 3,215,800

ELECTROMAGNETIC RELAY AND CONTACT CARRIER ASSEMBLY THEREFOR Filed July2, 1962 5 Sheets-Sheet 1 INVENTORS MAX HUPTER ERIK d. NIELSEN Nov. 2,1965 M- HURTER ETAL 3,215,800

ELECTROMAGNETIC RELAY AND CONTACT CARRIER ASSEMBLY THEREFOR Filed July2, 1962 5 Sheets-Sheet 2 45 J07 T J05 Fig MAX HUI? EEIK Lj- N/ELSEN BYNov. 2, 1965 M. HURTER ETAL 3,215,800

ELECTROMAGNETIC RELAY AND CONTACT CARRIER ASSEMBLY THEREFOR Filed July2:, 1962 5 Sheets-Sheet 3 I N VENTORS MAX H U1? TE 1? BYER/K (j NIEL SENNov. 2, 1965 M. HURTER ETAL ELECTROMAGNETIC RELAY AND CONTACT CARRIERASSEMBLY THEREFOR 5 Sheets-Sheet 4 Filed July 2, 1962 7 )6 JW M a {1i w5 m M 5 7/ 2) a Illll Wmm m A wflwwhnnf w [a M L lllll I!" H :n x Q w Rummmwmmmn m K 4 Z w fi Nov. 2, 1965 M. HURTER ETAL 3,215,800

ELECTROMAGNETIC RELAY AND CONTACT CARRIER ASSEMBLY THEREFOR Filed July2', 1962 5 Sheets-Sheet 5 F I BYEQ/K a. N/ELSEN United States Patent3,215,800 ELECTROMAGNETIC RELAY AND CONTACT CARRIER ASSEMBLY THEREFORMax Hurter, Riverside, Calif., and Erik J. Nielsen,

Mequon, Wis., assignors to Square D Company, Park Ridge, IlL, acorporation of Michigan Filed July 2, 1962, Ser. No. 206,624

25 Claims. (Cl. 200-104) This invention relates generally toelectromagnetic devices, and more particularly to electromagneticcontrol relays of the type adapted to be secured to a control panel andto form part of a control system for an electrically driven machine.

An object of the invention is to provide an improved multipoleelectromagnetic control relay.

Another object is to provide a smaller, more reliable, durable, and lesscostly multipole electromagnetic control relay which is also easier tomount, wire, and maintain than former control relays of the sameratings.

A further object is to provide an improved multipole electromagneticrelay comprising various sub-assemblies which can be readily assembledto form a complete relay and the complete relay can be readilydisassembled into the various sub-assemblies without the use of specialtools and without removing the wiring from a mounted and installedrelay.

Still another object is to provide an improved multipole electromagneticcontrol relay in which enclosed contacts are readily convertible fromnormally open to normally closed condition and in which the normallyopen or normally closed condition of each pole is readily ascertainableby exterior inspection of a completely assembled relay.

A still further object is to provide an improved multipoleelectromagnetic relay in which the contacts of each pole areindependently readily convertible from normally closed to normally opencondition and vice-versa and any possible combination of normally openand normally closed contacts may be obtained without adjustment orexchange'of the return spring.

Yet another object is to provide an improved multipole electromagneticrelay wherein the contacts of any pole can be readily removed to convertthe relay to a relay having fewer poles with increased electricalclearance between the remaining poles.

Other objects and advantages will become apparent from the followingdescription and the accompanying drawings in which:

FIGURE 1 is a perspective view of a four-pole relay constructed inaccordance with this invention;

FIGURE 2 is an exploded View of the relay of FIG- URE 1;

FIGURE 3 is a perspective view of a cover holding bracket for the relay;

FIGURE 4 is a cross sectional view taken substantially along line 4-4 ofFIGURE 5;

FIGURE 5 is a front view of the relay of FIGURES 1 and 2 as it mightappear when mounted on a vertical mounting panel;

FIGURE 6 is a cross sectional view taken substantially along line 6-6 ofFIGURE 5;

FIGURE 7 is a side view of the relay of FIGURES 1 and 2 showing thecover thereof in section and the cover holding bracket in itsnon-operative position;

FIGURE 8 is a cross sectional view taken substantially along line 88 ofFIGURE 5;

FIGURE 9 is a front view of the relay similar to FIGURE 5 but with thecover and certain other parts removed;

FIGURE 10 is a view showing partly in section the magnet supportassembly of the relay of FIGURES l and 2;

and on opposite sides thereof.

3,215,800 Patented Nov. 2, 1965 FIGURE 11 is a view of the magnetsupport assembly taken in the direction of arrows 1111 of FIGURE 10;

FIGURE 12 is a perspective view of the spring rest for the return springfor the movable contact carrier or yoke bar assembly of the relay ofFIGURES 1 and 2;

FIGURE 13 is a perspective view of a spring clip adapted to receive apin terminal of the coil of the relay of FIGURES 1 and 2;

FIGURE 14 is a perspective view of an eight-pole relay constructed inaccordance with the invention;

FIGURE 15 is a side view, partially in section, of the relay of FIGURE14 taken in the direction of arrows 1515 of FIGURE 16;

FIGURE 16 is a view, partially in section, taken substantially alongline 1616 of FIGURE 15;

FIGURE 17 is a fragmentary view showing normally open contacts of onepole of a relay constructed in accordance with the invention;

FIGURE 18 is a view similar to FIGURE 17, but with the normally opencontacts in the closed position thereof assumed upon energization of thecoil of the relay;

FIGURE 19 is a fragmentary view showing the normally closed contacts ofone pole of a relay constructed in accordance with the invention;

FIGURE 20 is a view similar to FIGURE 19, but with the normally closedcontacts in the open position thereof assumed upon energization of thecoil of the relay;

FIGURE 21 is an exploded perspective view of the movable contacts andassociated parts for one pole of a relay constructed in accordance withthe invention; and

FIGURE 22 is a fragmentary perspective view of the movable contactcarrier of a relay constructed in accordance with the invention.

FIGURE 1 shows a four-pole relay 10, the major parts and sub-assembliesof which are shown in FIGURE 2 and include a housing assembly 12, anarmature guide assembly 14, an encapsulated coil 16, a magnet supportassembly 18, a yoke bar or movable contact carrier assembly 20, a pairof identical stationary contact block assemblies 22, and a cover 24.

The housing assembly 12 includes a housing 26, a pair of identicalcover-holding brackets 28, and a pair of compression springs 30operatively associated respectively with the brackets 28, one spring 30being shown in FIG- URES 4 and 7. The housing 26 preferably is molded ofa suitable insulating material and has a pair of grooves 32, one ofwhich is shown in FIGURES 2, 4 and 7, extending upwardly from the basethereof and adapted to respectively receive the springs 30 and baseportions 34 (FIGURE 3) of the brackets 28. The base portion 34 of eachbracket 28 and its respective groove 32 are complementarily shaped sothat a hooked edge portion 35 of the base portion 34 engages a retainingshoulder (not shown) in the groove 32 and prevents removal of the baseportion laterally of the groove. The springs 30 are respectivelycompressed between the base portions 34 and a pair of shoulders 36, oneof which is shown in FIG- URE 7 and each of which closes an end of oneof the grooves 32.

Each bracket 28 includes a bent tab 38 (FIGURE 3) adapted to be receivedin one of a pair of open-ended slots 39 (FIGURES 7 and 9) locatedrespectively at the bottom of a pair of recesses 40 (FIGURES 2 and 7) inthe upper edge portions of the housing 26 adjacent corners Further, eachtab 38 includes a hook portion 41 adapted to engage an inner surface ofthe housing 26 and thereby retain the respective bracket 28 in position.Adjacent the slots 39 at the bottom of the recesses 40 are a pair ofcamming surfaces 43 respectively engageable by the tabs 38.

Each bracket 28 also has a hooked end portion 45 on the end thereofopposite the base portion 34, while the cover 24 is provided on the topthereof with a pair of grooves 48 adapted to receive the hooked endportions 45. The engagement of the tabs 38 in the slots 39 preventsaccidental disassembly of the relay by unintended striking of thebrackets 28, since the hooked end portions 45 must be raised out of thegrooves 48 against the force of the springs 30 before the cover 24 canbe removed. In assembling, movement of tabs 38 along the cammingsurfaces 43 raises the brackets 28 sufiiciently to enable sliding of thehooked end portions 45 into the grooves 48.

The armature guide assembly 14 includes a generally U-shaped armatureguide 50 preferably molded of a suitable insulating material and alaminated, generally E-shaped armature 52 of magnetic material securedtherein by a flat spring 54 retained in the guide 50 by a pair of stops53 thereon and extending through a pair of links 55 anchored in thearmature 52, asshown most clearly in FIGURE 8. The armature guide 50includes a pair of channel-shaped leg portions 49 and an aperturedbottom portion 51. The opposite ends of the spring 54 engage outerbottom surfaces of the leg portions 49 of the armature guide 50 and thecentral portion of the spring acts through the links 55 to urge a pairof shouldered portions 57 of the armature 52 into engagement with matingshoulders on the inner sides of leg portions 49 of the armature guide50.

The housing 26 is generally rectangular and is provided withchannel-shaped portions 59 and 60 formed respectively in a pair ofopposed side walls and adapted to receive and reciprocably guide thearmature guide 50 and associated. parts, forming the. armature. guideassembly 14. As can be seen in FIGURE 8, a pair of inner shoulderportions or abutments 62 and 61 are provided respectively in the channelportions 59 and 60 as stops adapted to be engaged respectively by a pairof outer shoulder portions 64 and 63 on the leg portions 49 of thearmature guide 50. For a purpose to be later described, and as shown inFIGURE 9, the inner groove of the channel portion 59 is wider than thatof the channel portion 60 and the leg portion 49 of the armature guide50 received in the channel portion 59 is thicker than the leg portion 49thereof received in the channel portion 60 by virtue of a built-up orenlarged portion 65 (FIGURE 9) along one edge thereof, the portion 65preventing reception of the armature guide 50 by the channel portions 59and 60 of the housing 26 except in the relative positions shown. Thatis, the leg portion 49 of the armature guide 50 having the enlarged edgeportion 65 thereon is wider than the groove of the channel portion 60and cannot be received therein, but it can ,be receivedin the groove ofchannel portion 59.

The encapsulated coil 16 .is provided with a pair of upstanding portions67 of the encapsulating material for supporting a pair of prongterminals 68. The portions 67 are provided with outer shoulders adaptedto be received in and supported by the bottom edges of a pair ofrecesses 69 in the top portions of the other pair of side walls of thehousing 26 (FIGURES 2 and 6).

The magnet support assembly 18 includes a channelshaped magnet support71 having a pair of extensions 72 projecting outwardly from oppositesides thereof and adjacent opposite ends. Each extension 72 has abracket 73 reciprocally mounted thereon, the brackets 73 respectivelyhaving a pair of apertures 73a therein adapted to respectively receivethe outer ends of the extensions 72, and the extensions 72 beingrecessed to receive the inner edge portions of the brackets adjacent theapertures. The apertures 73a also have respectively retained therein apair of compression springs 74. A generally E-shaped laminated magnet 76having a pair of shading coils 77 secured to the outer leg portionsthereof is retained in the magnet support 71 by a spring clip 78extending through a slot in the magnet 76 and through holes in oppositesides of the channel-shaped magnet support 71. Sponge rubber cushions 79and 80 are respectively provided in the magnet support 71 and around thecentral leg portion of the magnet 76 to act as shock absorbers andpermit the magnef 76 to be self-aligning for quieter operation.

The inner surfaces of the opposite side walls of the housing 26 havingthe recesses 69 therein are each provided on one side of the respectiverecess 69 with an upper groove 82 and a lower groove 84 respectivelyterminating in shoulders '83 and 85 (FIGURE 4). The extensions 72 of themagnet support 71 are adapted to fit within the respective grooves 82and abut the shoulders 83. Further, each bracket 73 has a flanged endportion 73b adapted to fit within an associated one of the grooves 84and abut one of the shoulders 85 under pressure from one of thecompression springs 74.

The yoke bar or movable contact carrier assembly 20 includes a yoke baror movable contact carrier 86 having a base portion 87, a handle portion88 extending from one side of the base portion 87 centrally thereof,four supporting posts 90 extending from the base portion 87 parallel tothe handle portion 88, and four crossbar portions 92 extending betweenthe posts 90 or between a post 90 and the handle portion 88,respectively. The base portion 87 includes a pair of depending lugs 94(FIGURE 8) adapted to be respectively received within the channelshapedleg portions 49 of the armature guide 50. For a purpose to be laterdescribed, the yoke bar or contact carrier 86 can be properly mounted onthe armature guide 50 in only one position relatively thereto. Thus, theouter ends of the channel-shaped leg portions 49 are recessed on oneside of the respective channels to receive a depending lip portion 95provided on only one of the long edges of the base portion 87, as bestshown in FIG- URE 4.

The handle portion 88 is apertured to receive a return spring 96 andshaped to slidingly receive a spring rest 97, shown best in FIGURE 12and having protruding ends 97a adapted to be engaged by the cover 24 asshown in FIG- URE 6. A pair of slots 97b in the spring rest 97respectively receive a pair of guiding and retaining portions 89 on thehandle portion 88.

The four crossbar portions 92 are adapted to support the movable contactassemblies each of which includes a contact finger 98 having a pair ofcontacts 98a formed thereon respectively adjacent opposite ends thereof,a spring rest 99, a contact support member 100, all shown best in FIGURE21, and a .contact spring 101 (FIGURES 4, 8, and 17-20). For a purposeto be later described, each crossbar portion 92 of the contact carrier86 includes a depending lug portion 93.

Each contact support member includes a pair of U-shaped portions 102(FIGURE 21), and each U-shaped portion 102 includes a bight. portion 103and a pair of leg portions 104 extending therefrom. The U-shapedportions 102 are joined at the respective ends of their leg portions 104opposite the bight portions 103 by a pair of transverse connectingportions 105 which are adapted to engage one of the crossbar portions 92of the contact carrier 86. The contact finger 98 of each movable contactassembly is recessed as at 98b to be slidingly received by the legportions 104 of a contact support 100 on the opposite side of a crossbarportion 92 from the connecting portions 105. The bight portions 103 ofeach contact support 100 retain the spring rest 99 of the respectivemovable contact assembly against the force of the respective contactspring 101 which is held under compression between the contact finger 98and the spring rest 99 of the movable contact assembly. 7 7

Each stationary contact block assembly 22 includes a contact block 107molded of insulating materialand recessed for the mounting of fourstationary contact connectors 108 (FIGURES 1 and 5) thereon in additionto a central coil terminal connector 109. The central coil terminalconnectors 109 of the two contact block assemblies are shown more fullyin FIGURE 6 and each includes a conductive strap 111 frictionally heldin a slot in the contact block 107, spring clip contacts jaws 112 bestshown in FIGURE 13 and riveted on the inner end of the strap 111 andadapted to receive a prong terminal 68 of the encapsulated coil 16, awire clamp 113, and a clamp ing screw 114 securing the wire clamp 113to' the outer end of the strap 111. Each spring clip contact jaw 112 isprovided with a pair of bent-out tabs 112a which engage the respectivecontact block 107 to further lock the conductive strap 111 therein.

A stationary contact connector 108 of one pole is shown in FIGURE 4 andincludes a conductive strap 116 frictionally held in a slot in thecontact block 107 by an interference fit with ribs in the slot which areshaved by the strip during assembly, a wire clamp 117 which may beidentical to the wire clamps 113, and a clamping screw 118 securing thewire clamp 117 to the outer end of the strap 116. The inner end of thestrap 116 is preferably provided on opposite sides with silver inlays116a forming stationary contacts. All of the stationary contactconnectors 108 are identical.

The cover 24 is apertured to receive the handle portion 88 of thecontact carrier 86, and in addition it is provided with four inspectionholes 120 (FIGURES 5 and 8) for a purpose to be later described.Depending portions 121 on the inner side of the cover respectivelyengage the contact support members 100 of movable contact assemblies inthe normally closed condition as defined hereinafter, whereby thecontact pressure is obtained by the contact springs 101 rather than bythe return spring 96.

To assemble the relay from the sub-assemblies, the armature guideassembly 14 is first placed in the housing assembly 12, the leg portion49 of the armature guide 50 having the enlarged edge portion 65 thereonbeing received in the groove of the channel portion 59 of the housing26. The encapsulated coil 16 is then placed in the housing 26, theupstanding portions 67 being aligned with the recesses 69 and the outershoulders engaging the bottom-s of the recesses (FIGURE 6). Next, themagnet support assembly 18 is placed in the housing with the magnet 76aligned with the armature 52 and extensions 72 of the magnet support 71in the grooves 82. The central leg portions of the E-shaped armature 52and magnet 76 protrude into a central opening in the coil 16 from thebottom and top thereof, respectively, as shown in FIGURES 6 and 8. Thebrackets 73 of the magnet support assembly .are then depressed againstthe forces of the springs 75 until the flange end portions 73brespectively enter the grooves 84. Upon release of the brackets 73, thesprings 74 urge the end portions 73b into engagement with the shoulders85 and also maintain the extensions 72 in engagement with the shoulders83. The magnet support assembly 18, the encapsulated coil 16, and thearmature guide assembly 14 are thus held within the housing assembly 12,the magnet assembly 18 and encapsulated coil 16 being fixed with respectto the housing 26, and the armature guide assembly 14 being reciprocablein the channel portions 59 and 60 and limited in one direction ofmovement by engagement of the armature 52 with the magnet 76 and limitedin the other direction of movement by engagement of the shoulderportions 64 and 63 on the armature guide 50 respectively with theshoulder portions 62 and 61 in the channel portions 59 and 60 of thehousing 26.

Next, the movable contact carrier assembly 20 is placed on the armatureguide 50, the lugs 94 being received in the leg portions 49 of thearmature guide (FIGURE 8), and

position or a normally closed contact position with respect to thestationary contacts 116a. When the relay 'is in use and the intendednormal positions of the movable contacts are unsymmetrical about theaxis of the handle portion 88 of the contact carrier 86 (for example,when the intent is that three of the poles should have normally-opencontacts and the other pole should have normally-closed contacts), andthe relay is disassembled for any reason, it is important that it bereassembled without unintended changing of the normal condition of thecontacts of any pole. For this reason, the enlarged portion 65 on thearmature guide 50 permits the armature guide assembly 14 to be assembledin the housing 26 in only one relative position out of two relativepositions which would be possible if the enlarged portion 65 wereomitted. Similarly, the lip portion on the base portion 87 of thecontact carrier 86 permits the movable contact carrier assembly 20 to beassembled to the armature guide assembly 14 in only one relativeposition out of two relative positions which would be possible if thelip portion 95 were omitted. The keying of the armature guide assembly14 to the housing 26 is not important or necessary in itself, butbecause the movable contact carrier assembly 20 is keyed to the armatureguide assembly 14, the movable contact carrier is thus keyed to thehousing and cannot be inadvertently reversed relative thereto.

After the movable contact carrier assembly 20 is in place on thearmature guide assembly 14, the stationary contact block assemblies 22are placed on the top of the housing 26 on opposite sides of the contactcarrier 86, the prong terminals 68 of the encapsulated coil 16 beingreceived in the contact jaws 112. Each contact block 107 is providedwith a central depending lug 107a (FIG URES 1 and 6) receivable in oneof the recesses 69 in the housing 26 above the portion 67 of the coil 16therein. Further, each contact block 107 is provided with a pair ofdepending outer end lugs 107b adapted to engage an outer surface of thehousing 26 and a :pair of depending inner lugs 1070, one of which can beseen in FIGURE 4, spaced between the end lugs 107b and the central lug107a and adapted to engage an inner surface of the housing 26. The lugs107a, 107b, and 107c on each contact block 107 prevent the block fromshifting laterally of the housing 26 once it is placed in assembledrelationship therewith. Each contact block 107 is also provided with arecess 107d (FIGUREZ) for receiving an end 97a of the spring rest 97 asshown in FIGURE 6.

The assembly is completed by placing the cover 24 in position over theouter end of the handle portion 88 of the contact carrier 86 and pushinginwardly on the two cover-holding brackets 28 to engage the hooked endportions 45 respectively in the grooves 48. During the movement of thebrackets 28, the bent tabs 38 will ride up the respective cammingsurfaces 43 and then snap down into the slots 39. When the tabs 38 arein the slots 39, the cover 24 is held firmly in position under theinfluence of the springs 30 by the hooked end portions 45 in the grooves48.

FIGURES 17-20 show the relative positions of the movable contacts 98aand the stationary contacts 11611 of one pole under four differentconditions. FIGURE 17 shows the contacts in a normally open position andFIGURE 19 shows the contact-s in a normally closed position, it beingunderstood that in accordance with the invention the contacts of eachpole may be readily converted from normally-open condition tonormally-closed condition and vice versa without any effect on the forcerequired to operate the relay, regardless of whether the contacts of therelay are all normally open or all normally closed or some are normallyopen and the rest normally closed.

To convert from normally open to normally closed contacts or vice versa,after disengaging the brackets 28 and removing the cover 24 and onestationary cont-act block assembly 22, the contact finger 98 of any polemay be pressed to rotate it through a half circle about its crossbarportion 92, the contact finger 98, contact support member 100, springrest 99, and spring 101 rotating about the cross bar portion 92 as aunit. The leg portions 104 of the contact support 100 are spaced fartherapart in the direction of the connecting portions 105 than the width ofthe cross bar portions 92 toprovide sutficient clearance for thisrotation, and the distance between the contact finger 98 and theconnecting portions 105 during the rotation increases as necessary byyielding of the spring 101. Thus, it will be seen in FIGURE 19 that themovable contact assembly has been rotated through a 'half circle aboutthe cross bar portion 92 from the relative position thereof in FIGURE17.

FIGURE 18 shows the closed position of normally open contacts of FIGURE17, the closed position thereof occurring when the relay is operatedeither by energization of the coil 16 or by manual operation of thehandle portion 88 of the movable contact carrier 86.

FIGURE 20 shows the open position of the normally closed contacts ofFIGURE 19, the open position oc curring when the relay is energized ormanually operated.

The condition of the contacts of any pole with regard to whether theyare normally open or normally closed is ascertained by inspectionthrough the holes 120'in the cover 24. If the contacts of a pole arenormally closed, the spring rest 99 for that pole are the cover and isreadily visible through the respective hole 120. If the contacts of ahole are normally open, nothing can be seen through the respective hole120.

For a relay in which normally open contacts close at the same timenormally closed contacts open, the force required to operate the relayis the same regardless of whether the contacts of the various poles arenormally open or normally closed. To this end, the thickness of thecross bar portion 92 of each pole excluding the depending lug portion 93is substantially equal to onehalf the stroke of the armature guideassembly 14 and movable contact carrier assembly 20, and the thicknessof the depending lug portion 93 is also substantially equal to one-halfthe stroke. Further, the contact support 100 straddles the lug portion93 so that the connecting portions 105 directly engage the cross barportion 92 in the normally closed position of the contacts (FIGURE 19)and the contact finger 98 is spaced from the cross bar portion 92 by adistance equal to one-half of the stroke of the movable contact carrier86 or equal to the thickness of the depending lug portion 93. Inaddition, the lug portion 93 spaces the contact finger 98 away from thecross bar portion 92 in the normally open position of the contacts(FIGURE 17) by-a distance equal to one-half the stroke of the contactcarrier. By this arrangement, the length of the spring 101 is the samein the normally open condition of the contacts (FIGURE 17) as in thenormally closed condition of the contacts (FIGURE 19) when the coil 16of the relay is not energized.

If a pole has normally open contacts as shown in FIGURE'17 and the coil16 of the relay is energized, the movable contact carrier 86 will moveone-half of its stroke before the movable contacts 98a on the contactfinger 98 engage the stationary contacts 116a, and during the last halfof the stroke the spring 101 will be compressed one-half the length ofthe stroke to the length shown in FIGURE 18. Similarly, if a pole hasnormally closed contacts as shown in FIGURE 19 and the coil 16 of therelay is energized, the movable contact carrier 86 will move one-half ofits stroke before the movable contacts 98a on the contact finger 98become disengaged from the stationary contacts 116a, and during the lasthalf of the stroke the spring 101 will be compressed one-half the lengthof the stroke to the length shown in FIGURE 20, and the length of thespring 101 is the same in the closed position of the normally opencontacts (FIGURE 18) as in the open position of the normally closedcontacts (FIGURE 20).

Since the length of the spring 101 when'the coil 16 is deenergized isthe same for normally open and normally closed contacts, and since thespring 101 is compressed when the coil 16 is energized to a new lengthwhich is the same for closed normally open contacts and open normallyclosed contacts, it follows that the force required to operate the relayis the same regardless of whether the contacts are all normally open,all normally closed, or some are normally open and'the rest normallyclosed.

FIGURES 14, 15, and 16 show an eight-pole relay in views similar toFIGURES l, 4, and 8, respectively, of the four-pole relay. The housing26, the armature guide assembly 14, the magnet support assembly 18, andthe cover 24 are identical for both relays and identically numbered andnot herein further described.

The coil 216 of the eight-pole relay is substantially identical to thecoil 16 of the four-pole relay, the only difference being that the coil216 has a different number of turns of wire than the coil 16, in orderto be able to generate a slightly larger electromagnetic force.

The cover-holding brackets 228 of the eight-pole re lay are similar tothe brackets 28 of the four-pole relay, the end portions being identicalbut the body portions of the brackets 228 being longer and having lessangular ity therein, as can be seen in a comparison of FIGURES 4 and 15.

The movable contact carrier assembly 220 of the eight- .pole relay issimilar to the movable contact carrier assembly 20 of the four-polerelay, but the handle portion 288 and supporting posts 290 of theeight-pole relay are longer than the handle portion 88 and supportingposts 90 of the four-pole relay, in order to provide supportingstructure for two rows of movable contact assemblies, each row havingthe movable contacts for four poles.

The stationary contact block assemblies 222 of the eight-pole relay aresimilar to the stationary contact block assemblies 22 of the four-polerelay, but the contact blocks 307 of the eight-pole relay are tallerthan the contact blocks 107 of the four-pole relay, in order to providesupporting structure for two rows of stationary contact connectors,those of the upper row being identical to the stationary contactconnectors 108 previously described, but the stationary contactconnectors 308 of the lower row having the conductive straps 316 thereofreversely bent as shown in FIGURE 15 to provide for ease of access tothe clamping screws 318 thereof. Each contact block 307 also is providedwith a plurality of projecting portions 321 which extend into themovable contact carrier'assembly 220* and are engaged by the contactsupport members of movable contact assemblies of the lower row which arein normally closed contact position. The projecting portions 321 on thestationary contact blocks 307 thus function with respectto the lower rowof movable contact assemblies in the same manner as the dependingportions 121 on the cover 24 function with respect to the upper row ofmovable contact assemblies.

Various modifications may be made in the structure disclosed withoutdeparting from the spirit and scope of the invention.

We claim:

1. In an electromagnetic relay,

(a) a linearly reciprocable contact carrier assembly including acrossbar portion,

(b) an elongated contact finger having a pair of contact portionsthereon respectively adjacent opposite ends thereof, and

(0) means mounting said contact finger on said crossbar portion forrotary movement thereabout.

2. In an electromagnetic relay,

(a) a movable contact carrier assembly linearly reciprocable through apredetermined length of stroke and including a crossbar portion having athickness 9 in the direction of said stroke substantially equal to thelength of said stroke,

(b) an elongated contact finger having a pair of contact portionsthereon respectively adjacent opposite ends thereof, and

(c) means mounting said contact finger on said crossbar portion forrotary movement thereabout.

3. In an electromagnetic relay,

(a) movable contact carrier assembly linearly reciprocable through apredetermined length of stroke and including a crossbar portion having apair of opposed outer generally fiat surfaces extending perpendicularlyto the direction of said stroke defining a thickness of said crossbarportion substantially equal to the length of said stroke,

(b) an elongated contact finger having a pair of contact portionsthereon respectively adjacent opposite ends thereof, and

() means mounting said contact finger on said crossbar portion forrotary movement thereabout from a position in which it engages one ofsaid flat surfaces to a position in which it engages the other of saidflat surfaces.

4. In an electromagnetic relay,

(a) a linearly reciprocable contact carrier assembly including acrossbar portion having a lug portion depending centrally from one sidethereof, and

(b) a movable contact assembly mounted on said crossbar portion, saidmovable contact assembly includ- 111g 1) a contact support memberrotatably mounted on said crossbar portion, said contact support memberincluding a pair of generally U-shaped portions spaced apart from eachother on opposite sides of said crossbar portion, each U-shaped portionincluding a bight portion and a pair of leg portions extendingtherefrom, said U-shaped portions being joined by a pair of transverseconnecting portions extending substantially perpendicularly to saidcrossbar portion, one of said connecting portions joining a free endportion of one of the leg portions of one U-shaped portion with a freeend portion of one of the leg portions of the other U-shaped portion andthe other of said connecting portions joining a free end portion of theother of the leg portions of said one U-shaped portion with a free endportion of the other of leg portions of said other U-shaped portion, thesides of said connecting portions nearest said bight portions beingengageable with said crossbar portion and said connecting portions onthe opposite side of said crossbar portion from said bight portions inany position to which said contact support member is rotated on saidcrossbar portion, said connecting portions and the leg portions of eachof said U-shaped portions being spaced apart to straddle said lugportion of said crossbar portion,

(2) an elongated contact finger extending substantially perpendicularlyto said crossbar portion through said U shaped portions on the oppositeside of said crossbar portion from said con necting portions and beingsupported by said U-shaped portions for reciprocal movement toward andaway from said crossbar portion, said contact finger having a pair ofcontact portions thereon respectively adjacent opposite ends thereof andon the side thereof facing said crossbar portion,

(3) a spring rest extending through said U-shaped portions and beingsupported by said bight portions, and

(4) a compression spring having one end seated on said spring rest andthe other end seated on said contact finger,

5. In an electromagnetic relay, a linearly reciprocable contact carrierassembly as claimed in claim 4, wherein said lug portion has a thicknessin the direction of reciprocal movement of said contact carrier assemblysubstantially equal to one-half of the length of the stroke of saidcontact carrier assembly.

6. In an electromagnetic relay, a linearly reciprocable contact carrierassembly as claimed in claim 4, wherein said crossbar portion exclusiveof said lug portion has a thickness in the direction of reciprocalmovement of said contact carrier assembly substantially equal to onehalfof the length of the stroke of said contact carrier assembly and saidlug portion also has a thickness in said direction substantially equalto one-half of the length of said stroke.

7. In an electromagnetic relay, a contact carrier assembly as claimed inclaim 6, including a plurality of said crossbar portions axially alignedin a row and a plurality of said movable contact assemblies respectivelymounted on said crossbar portions.

8. In an electromagnetic relay, a contact carrier assembly as claimed inclaim 7, including a plurality of said rows of said crossbar portionsand a plurality of said movable contact assemblies respectively mountedon said crossbar portions in said rows.

9. In an electromagnetic relay, a contact carrier assembly as claimed inclaim 4, including a plurality of said crossbar portions axially alignedin a row and a plurality of said movable contact assemblies respectivelymounted on said crossbar portions.

10. In an electromagnetic relay, a contact carrier assembly as claimedin claim 9, including a plurality of said rows of said crossbar portionsand a plurality of said movable contact assemblies respectively mountedon said crossbar portions in said rows.

11. An electromagnetically and manually operable relay comprising (a) ahousing,

(b) an armature guide reciprocably mounted in said housing and carrying.an armature for movement integrally therewith,

(c) a coil in said housing disposed in electromagnetic relationship withsaid armature and having a pair of prong terminals extending outwardlyfrom an end of said housing,

(d) a magnet support secured to said housing and retaining said coil andarmature guide therein, said magnet support carrying a magnet disposedin electromagnetic relationship With said coil and armature,

(e) a pair of stationary contact block assemblies mounted on said end ofsaid housing in spaced-apart relationship, each of said stationarycontact block assemblies including (1) a central coil terminal connectorelectrically connected to one of said prong terminals, and (2) aplurality of stationary contact connectors generally aligned with saidcentral coil terminal connector, each of said stationary contactconnectors including a conductive strap having a pair of stationarycontact surfaces respectively on opposite sides of an inner end thereof,

(f) a movable contact carrier assembly interposed between saidstationary contact block assemblies and engageable by said armatureguide for movement therewith, said contact carrier assembly including('1) a manually operable central handle portion,

(2) a plurality of crossbar portions movable integrally with said handleportion, and

(3) a plurality of elongated contact fingers respectively rotatablymounted on said crossbar portions, each of said contact fingers having apair of contact portions thereon respectively adjacent opposite ends ofone side thereof and engageable with stationary contact'surfaces of re-(1)a' manually operable central handle portion, spective stationarycontact connectors on said (2) a plurality of crossbar portions movableinte stationary contact block assemblies, said congrally wit-h saidhandle portion and each having tact fingers being rotatably adjustableto a nora lugportion depending centrally from one side mally'opencontact position with respect to the 5 thereof, and stationary contactsurfaces on one side of re ("3) a plurality of movable contactassemblies respective conductive straps of said stationary conspectively rotatably mounted on said crossbar tact connectors on saidstationary contact block port-ions, each of said movable contactassemassemblies and being rotatably adjustable to a bles includingnormally closed contact position with respect to (a) a contact supportmember rotatably the stationary contact surfaces on the other sidesupported on its. respective crossbar porof said respective conductivestraps, and tion, I v

(g) a cover clamped to said housing to retain said sta- (b) an elongatedcontact finger,

- tionary contact block assemblies thereon, said cover (c) a contactspringgand I being apertured to receive said handle portion. '(d) aspring rest, each of said contact. sup- 12. A relay as claimed in claim11, wherein said'cover has a plurality of inspection holes for aifordingvisual indication of the normally open cont-act position and normallyclosed contact-position of said contact fingers.

13. A relay as claimed in claim 11, including a spring including a bightportion and a pair of leg rest carried by said movable contact carrierassembly and portions extending therefrom, said U- engaged with an innerside of said cover, and a return shaped portions of. each contactsupport .spring-seated-on said spring rest for returning said movablemember being joined by a pair of transcontact carrier assembly and saidarmature guide to norverse connecting portions extending submal positionupon deenergization of said coil. A stantially perpendicularly to therespec- 14. In an electromagnetic device tive crossbar portion, one ofsaid connect- (a) 'a housing, A 7 ing portions joining a free endportion of .(b)- anar-mature guide reciprocably mounted in said one ofthe leg portions of one U-shaped housing and limited in one direction ofits movement portion with a free end portion of one of by stops adjacentone end of said housing, said arma the leg portions of the otherU-shaped porture guide carrying an armature adjacent said one tion andthe other of said connecting porend of said housing for movementintegrally theretions joining a free end portion of the othwith, er ofthe leg portions of said one U-shaped (c) a coil in said housingdisposed in electromagnetic portion .with 'a free end portion of therelationship with said armature, 7 other of therleg portions of saidother U- (d) a magnet support on the opposite side of said coil shapedportion, the sides of said -connectfrom said armature, and ing portionsnearest the respective bight (e) a magnet carried by said magnet supportand disportions being engageablewith the respecposed in electromagneticrelationship with said coil tive crossbar portion and said connectingand armature, said magnet support being releasably 40 portions being onthe opposite side of the secured to said housing adjacent the other endthererespective crossbar portion from the reof by a pair ofspring-biased brackets disposed therespective bight portions in anyposition to in, thereby to retain said coil and armature guide whichttherespective contact support memtherein, and said armature guide beinglimited in the her i t t d on it crossbar -ti id other direction of itsmovement by operative engageconnecting portions and the leg portions ofment of said armature with said magnet. 7 each of said Uashaped portionsof each 15. An electromagnetically and manually operable re- I "contactsupport member being spaced-apart lay comprising to straddle the lugportion of the respec- (a) a housing, tive crossbar portion, eachelongated con- (b) an armature guide reciprocably mounted in said tactfinger extending substantially perpendi housing and carrying an armaturefor movement inte- 5O cularly to the respective crossbar portion grallytherewith, I through the -U-shaped portions of the re- (c) a coil insaid housing disposed in electromagnetic spective contact support memberon the oprelationship with said armature and having a pair posite sideof the respective crossbar porof terminals extending outwardly from anend of tion from the connecting portion of th said housing, I respectivecontact support member and be- (d) a magnet support releas-ably securedto said housing supported by the respective U-shaped ing and retainingsaid coil and armature guide thereortions for reciprocal movement towardin, said magnet support carryinga magnet disposed andaway from therespective crossbar porin electromagnetic relationship with said coiland v tion, each contact finger having a pair of armature contactportions thereon respectively ad- (e) a pair of stationary contact blockassemblies jacent o i d th bf On h id mounted on said end of saidhousing in spaced-apart thereof f i the respective crossbarrelationship, each of said stationary contact block tion andrespectively engageable with assembhes Including, ti'onary contactsurfaces of respective sta- (1) a central coil terminal connectorelectrically tionary Contact connectors on Said Statiom connected to oneof said coil terminals, and ary Contact block assemblies, each Spring(2) a plurality of stationary contact connectors, rest extending throughthe U shaped Pop each of said stationary contact connectors includd b Irt db th bi ht op ing-a conductive strap having a pair of stationary Itions an emg P e e g p contact surfaces respectively on opposite sidesHons of the respectlvefiqntact f l of aninnel. end thereof ber, eachcontact sprlng having one end (f) a movable contact carrier assemblyinterposed bel 011 e p ctive sprlng rest and the tween said stationarycontact block assemblies and other end seated on h p Contact engageableby said armature guide for movement finger, each movable contactassembly betherewith, said contact carrier assembly including ingrotatably adjustable (in the respective port members including a pair ofgenerally Uashaped portions spaced-apart from each other on oppositesides of the respective crossbar portion, each U-shaped portion crossbarportion to position the respective contact finger on the side of thecrossbar portion having the lug portion there-on and in a normally opencontact position with respect to the contact portions thereon and thestationary contact surfaces on one side of respective conductive strapsof said stationary contact connectors on said stationary contact blockassemblies and being rotatably adjustable to position the respectivecontact finger on the opposite side of the respective crossbar portionfrom the lug portion thereon and in .a normally closed contact positionwith respect to the contact portions thereon and the stationary contactsurfaces on the other side of said respective conductive straps, and

(g) a cover clamped to said housing to retain and stationary contactblock assemblies thereon, said cover being apertured to receive saidhandle portion.

16. A relay as claimed in claim 15, wherein said cover has a pluralityof inspection holes for aiford-ing a visual indication of the normallyopen contact position and normally closed contact position of saidcontact fingers.

17. A relay as claimed in claim 15, wherein each of said lug portionshas a thickness in the direction of recip rocal movement of said contactcarrier assembly substan tially equal to one-half of the length of thestroke of said contact carrier assembly.

18. A relay as claimed in claim 15, wherein each of said crossbarportions exclusive of the respective lug portions has a thickness in thedirection of reciprocal movement of said contact carrier assemblysubstantially equal to onehalf of the length of the stroke of saidcontact carrier assembly and each of said lug portions also has athickness in said direction substantially equal to one-half of thelength of said stroke.

19. A relay as claimed in claim 18, wherein said cover has portionsengaging the contact support member of any movable contact assemblywhich is in a normally closed contact position.

20. A relay as claimed in claim 15, wherein said cover has portionsengaging the contact support member of any movable contact assemblywhich is in a normally closed contact position.

21. An electromagnetically and manually operable relay comprising (a) ahousing,

(b) .an armature reciprocably mounted in said housing adjacent one endthereof,

(c) an energizable coil and a magnet in said housing disposed inelectromagnetic relationship with said armature,

(d) a pair of individual stationary contact block assemblies separatefrom said housing and mounted -on the other end thereof in spaced-apartrelationship, said block assemblies each having a plurality of terminalswhich are provided with stationary contacts,

(e) a movable contact carrier assembly between said block assemblies,said movable contact carrier assembly carrying a plurality of movablecontacts respectively cooperable with the stationary contacts of saidblock assemblies and being movable by said armature upon ener-gizationof said coil and having a manually operable handle portion movableintegrally therewith and projecting outwardly from between said blockassemblies,

(f) a cover engaging said block assemblies and having an aperture inwhich said handle portion is reciprocably received, and

(g) a pair of clamps mounted on said housing and having portionsengageable with said cover on the opposite side thereof from said blockassemblies and being spring biased to retain the housing, blockassemblies, movable contact carrier assembly, and cover in assembledrelationship.

22. A relay as claimed in claim 21, wherein said movable contacts arereadily convertible from normally open to normally closed condition andvice-versa with respect to said stationary contacts and said cover isprovided with a plurality of inspection holes for affording visualindication of the condition of said movable contacts with respect towhether they are normally open or normally closed in relation to saidstationary contacts.

23. A relay as claimed in claim 22, wherein said movable contact carrierassembly includes a plurality of contact springs operatively connectedrespectively to said movable contacts and said cover has portionsoperatively engaging the contact spring of any movable contact which isin normally closed condition.

24. A relay as claimed in claim 21, including a spring rest carried bysaid movable contact carrier assembly and engaged with an inner side ofsaid cover, and a return spring seated on said spring rest for returningsaid movable contact carrier assembly and said armature to normalposition upon deenergization of said coil.

25. An electromagnetic relay comprising (a) a housing,

(b) an encapsulated coil in said housing having a pair of prongterminals extending outwardly therefrom toward an end of said housingadjacent opposite sides thereof, and

(c) a pair of stationary contact block assemblies mounted on said end ofsaid housing, each of said =block assemblies including a plurality ofsubstantially aligned electrical connectors a central one of which isprovided with a pair of spring clip contact jaws in which one of saidprong terminals is received, and the remainder of which are respectivelyprovided with stationary contacts for the relay.

References Cited by the Examiner UNITED STATES PATENTS BERNARD A.GILHEANY, Primary Examiner.

ROBERT K. SCHAEFER, Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No 3 215,800 November 2 1965 Max Hurter et alt It is hereby certified that errorappears in the above numbered patent requiring correction and that thesaid Letters Patent should read as corrected below.

Column 5, line 1, for "contacts" read contact column 7, line 26, for"are" read abuts line 28, for "hole", second occurrence, read Y pole xcolumn 9, line 13, after "stroke" insert and line 52, before "on" insertH being column 13, line 18, for "and" read M said Signed and sealed this7th day of June 1966? (SEAL) Attest:

EDWARD J. BRENNER Commissioner of Patents ERNEST W. SWIDER AttestingOfficer

11. AN ELECTROMAGNETICALLY AND MANUALLY OPERABLE RELAY COMPRISING (A) AHOUSING, (B) AN ARMATURE GUIDE RECIPROCABLY MOUNTED IN SAID HOUSING ANDCARRYING AN ARMATURE FOR MOVEMENT INTEGRALLY THEREWITH, (C) A COIL INSAID HOUSING DISPOSED IN ELECTROMAGNETIC RELATIONSHIP WITH SAID ARMATUREAND HAVING A PAIR OF PRONG TERMINALS EXTENDING OUTWARDLY FROM AN END OFSAID HOUSING, (D) A MAGNET SUPPORT SECURED TO SAID HOUSING AND RETAININGSAID COIL AND ARMATURE GUIDE THEREIN, SAID MAGNET SUPPORT CARRYING AMAGNET DISPOSED IN ELECTROMAGNET RELATIOHSHIP WITH SAID COIL ANDARMATURE, (E) A PAIR OF STATIONARY CONTACT BLOCK ASSEMBLIES MOUNTED ONSAID END OF SAID HOUSING IN SPACED-APART RELATIONSHIP, EACH OF SAIDSTATIONARY CONTACT BLOCK ASSEMBLIES INCLUDING (1) A CENTRAL COILTERMINAL CONNECTOR ELECTRICALLY CONNECTED TO ONE OF SAID PRONGTERMINALS, AND (2) A PLURALITY OF STATIONARY CONTACT CONNECTORSGENERALLY ALIGNED WITH SAID CENTRAL COIL TERMINAL CONNECTOR, EACH OFSAID STATIONARY CONTACT CONNECTORS IONCLUDING A CONDUCTIVE STRAP HAVINGA PAIR OF STATIONARY CONTACT SURFACES RESPECTIVELY ON OPPOSITE SIDES OFAN INNER END THEREOF, (F) A MOVABLE CONTACT CARRIER ASSEMBLY INTERPOSEDBETWEEN SAID STATIONARY CONTACT BLOCK ASSEMBLIES AND ENGAGEABLE BY SAIDARMATURE GUIDE FOR MOVEMENT THEREWITH, SAID CONTACT CARRIER ASSEMBLYINCLUDING (1) A MANUALLY OPERABLE CENTRAL HANDLE PORTION, (2) APLURALITY OF CROSSBAR PORTIONS MOVABLE INTEGRALLY WITH SAID HANDLEPORTION, AND (3) A PLURALITY OF ELONGATED CONTACT FINGERS RESPECTIVELYROTATABLY MOUNTED ON SAID CROSSBAR PORTIONS, EACH OF SAID CONTACTFINGERS HAVING A PAIR OF CONTACT PORTIONS THEREON RESPECTIVELY AD JACENTOPPOSITE ENDS OF ONE SIDE THEREOF AND ENGAGEABLE WITH STATIONARY CONTACTSURFACES OF RESPECTIVE STATIONARY CONTACT CONNECTORS ON SAID STATIONARYCONTACT BLOCK ASSEMBLIES, SAID CONTACT FINGERS BEING ROTATABLYADJUSTABLE TO A NORMALLY OPEN CONTACT POSITION WITH RESPECT TO THESTATIONARY CONTACT SURFACES ON ONE SIDE OF RESPECTIVE CONDUCTIVE STRAPSOF SAID STATIONARY CONTACT CONNECTORS ON SAID STATIONARY CONTACT BLOCKASSEMBLIES AND BEING ROTATABLY ADJUSTABLE TO A NORMALLY CLOSED CONTACTPOSITIONWITH RESPECT TO THE STATIONARY CONTACT SURFACES ON THE OTHERSIDE OF SAID RESPECTIVE CONDUCTIVE STRAPS, AND (G) A COVER CLAMPED TOSAID HOUSIONG TO RETAIN SAID STATIONARY CONTACT BLOCK ASSEMBLIESTHEREON, SAID COVER BEIONG APERTURED TO RECEIVE SAID HANDLE PORTION.